Methods and systems for ascertaining the roughness of a print media surface

ABSTRACT

In one embodiment, a printing device comprises a printer configured to print upon paper, a surface-engaging member associated with the printer and configured to physically engage a paper surface, the surface-engaging member comprising a flexure material body that is supported in a cantilevered disposition proximate a piece of paper to be printed upon by the printer, a reflective member joined with the surface-engaging member, one or more light sources in operable proximity to the reflective member and configured to project light energy toward the reflective member, and a position detector mounted in operable proximity to the reflective member and configured to receive light energy that is reflected from the reflective member, the surface-engaging member being configured for displacement by the paper&#39;s surface in accordance with variations in the roughness of the surface sufficiently so that light that is reflected by the reflective member and received by the position detector can be utilized to ascertain a measure of the paper surface&#39;s roughness.

RELATED APPLICATIONS

This is a continuation application of and claims priority to Ser. No.10/251,391 filed on Sep. 20, 2002, now U.S. Pat. No. 6,629,452 which, inturn, is a divisional application of and claims priority to Ser. No.09/640,464, filed Aug. 15, 2000, now U.S. Pat. No. 6,477,892, thedisclosures of which are incorporated by reference herein.

TECHNICAL FIELD

The present invention relates to methods and systems for ascertainingthe roughness of a print media surface. More particularly, aspects ofthe invention relate to printing methods and systems that ascertain theroughness of a print media surface.

BACKGROUND

There are many reasons why it is beneficial to ascertain the roughnessof a print media surface such as a paper surface. For example, inmanufacturing processes, it is desirable for paper to be of a generallyuniform roughness. By ascertaining the roughness of a paper surface, onecan ascertain whether paper that is mass produced has a uniform degreeof roughness. In printing processes, roughness determinations can assistin setting certain printing parameters, such as the amount of toner thatis used and the toner parameters that govern the toner's use.

In manufacturing scenarios, there have been methods and systems evolvefor ascertaining the roughness of a paper surface. One typical method isthe so-called Parker Surface Roughness Test (Print Surf) method. Thismethod measures the air which passes between the surface of a coatedpaper and a flat surface of either steel or rubber. The apparatus thatis used to carry out such a test is very expensive, is not portable, andrequires a laboratory staff and space. More importantly the test lacks ahigh resolution for the smoothest surfaces.

In printing scenarios (such as electrostatographic reproduction ofimages, e.g. electrophotography, and laser printing, as well as thermalink jet, and thermal transfer reproduction of images), copy quality issensitive to and can be affected by the level of roughness of the paper.Distinct variations can exist as to the level of paper roughness foundin individual copy sheets, such as paper, that are used in printingdevices. Additionally, individuals using such printing devices aretypically free to switch the print media or paper upon which printingtakes place. For example, in an office environment, less expensive draftpaper might be used for preparing draft versions of different documents,while more expensive paper might be used for final versions of thedocuments. The characteristics of these different types of paper,including roughness, can vary widely.

Various machine parameters can be affected by the roughness of the paperto be processed through the machine. Based on the paper's roughnesslevel, these parameters can be adjusted for their optimum functionalitywithin the machine as well as for achieving optimum copy quality. Forexample, an ideal goal in electrophotography is to have the correctamount of toner deposited onto a copy sheet on a continuous basis. Withpoor development control two situations occur. First, concerning avariability of toner quantity applied, too little toner creates lighterimages, where too much toner creates darker images and may cause tonerto appear in non-image areas. Second, concerning the machine, too muchtoner development causes excess toner waste which increases the expenseof running the machine. Replacement of these components is therebyrequired on a more frequent basis. The need for precise toner control isintensified in color development systems where individual color imagesare superimposed on each other to create the full color image.

A rougher paper surface contains a greater surface area than a smootherpaper surface, and may therefore require application of a higherdeveloped toner mass per unit area to get the same dark, uniform, sharpcopy quality. Additionally, if a greater amount of toner is required ona rougher paper surface, the development voltage, and/or the tonerconcentration, and/or the fuser set temperature must be raised to assurethat the toner is completely fused to the paper. Under-fused toner on asubstrate creates toner adhesion and durability issues which can includesmears, flaking toner at paper folds, and integrity during handling. Anincreased voltage may also be required for the corona generating devicesassociated with both the charging element, as well as the transferelement, for a rougher surface paper requiring a greater amount of tonerdeposited thereon. Uniformly increasing machine parameters such as thefuser set temperature, fuser dwell time, or voltage level to thecharging device, transfer device or developer may eliminate certain copyquality problems on rougher surface papers, however, other negativefactors can be created. For example, increased stress on these affectedcomponents causes the need for more frequent component repair orreplacement. Furthermore, the increased power required to run thecomponent at the higher settings can result in increased energyconsumption and cost. Machines that can optimize copy quality as well asinternal processing operations will have a greater latitude of operationand a competitive edge.

Several widely used, indirect, methods of paper surface roughnessmeasurement, characterized as Sheffield smoothness, Bekk smoothness andParker Print Surf (described above), include air leak techniques whichmeasure the volume of air that leaks, over a fixed time interval,between the paper surface and a test equipment seal, or, conversely, thetime required for the leakage of a fixed air volume. Although theseindirect surface roughness measurement methods offer a numericallyquantified, relative value of surface roughness, they have not proven tobe consistent, reliable indicators of print quality.

Accordingly, this invention arose out of concerns associated withproviding improved methods and systems for ascertain the roughness of aprint media surface.

SUMMARY

In one embodiment, a printing device comprises a printer configured toprint upon paper, a surface-engaging member associated with the printerand configured to physically engage a paper surface, thesurface-engaging member comprising a flexure material body that issupported in a cantilevered disposition proximate a piece of paper to beprinted upon by the printer, a reflective member joined with thesurface-engaging member, one or more light sources in operable proximityto the reflective member and configured to project light energy towardthe reflective member, and a position detector mounted in operableproximity to the reflective member and configured to receive lightenergy that is reflected from the reflective member, thesurface-engaging member being configured for displacement by the paper'ssurface in accordance with variations in the roughness of the surfacesufficiently so that light that is reflected by the reflective memberand received by the position detector can be utilized to ascertain ameasure of the paper surface's roughness.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side elevational view of an exemplary print media roughnessdetection mechanism in accordance with one described embodiment.

FIG. 2 is a top plan view of an exemplary surface-engaging member inaccordance with one described embodiment.

FIGS. 3 and 4 are side elevational views of exemplary surface-engagingmembers in accordance with two described embodiments.

FIG. 5 is a side elevational view of various tip portion constructionsin accordance with the described embodiments.

FIG. 6 is a side elevational view of an exemplary device in which aninventive print media roughness detection mechanism can be employed.

FIG. 7 is a side sectional view of a portion of the exemplary device ofFIG. 6 which shows but one manner in which an inventive print mediaroughness detection mechanism can be employed.

FIG. 8 is a high level block diagram of an exemplary control system inaccordance with the described embodiment.

FIG. 9 is a flow diagram that describes steps in a method in accordancewith the described embodiment.

DETAILED DESCRIPTION

Print Media Roughness Detector

FIG. 1 shows a print media roughness detection mechanism 10 inaccordance with one embodiment. In this particular embodiment, the printmedia comprises paper. It is to be understood, however, that other printmedia that are not necessarily paper in nature could be used inconnection with the techniques described below. Examples of such otherprint media include, without limitation, transparencies and glossies.

In this particular embodiment, the detection mechanism comprises asurface engaging member 12 that is configured to physically engage thesurface of a piece of paper as shown. The surface engaging member 12 canbe supported in any manner in which it can engage the surface of a pieceof paper. The surface engaging member is mounted on some type of supportstructure 13 which, in one example described below, can comprise theinternal structure of a printing device such as a laser or ink jetprinter. The surface engaging member 12 is, in this example, supportedin a cantilevered disposition over the paper's surface. It will beappreciated, however, that other operable dispositions could be utilizedwithout departing from the spirit and scope of the invention.

A reflective member 14 is provided and, in this example, is joined withthe surface engaging member. Any suitable reflective material can beutilized for the reflective member. The reflective member can comprisean integral part or component of the surface engaging member 12.Alternately, the reflective member can comprise a separate part orcomponent that is connected to the surface engaging member 12. One ormore light sources or types of light sources are provided, with anexemplary light source 16 being shown mounted in operable proximity tothe reflective member 14. Any suitable light source can be utilized. Forexample, a suitable laser or LED source can be used to implement lightsource 16. In addition, a position detector 18 is provided and ismounted in operable proximity to reflective member 14. The positiondetector can comprise any suitable position detector from which relativeposition can be ascertained from reflected light. For example; aphoto-detector such as a photodiode can be utilized to implement theposition detector. Additionally, position-sensing photodiodes (PSDs) canbe utilized.

In practice, as relative movement occurs between the surface engagingmember 12 and the paper surface due to the roughness of the paper'ssurface, the surface engaging member 12 will be displaced (in thisexample vertically) an amount that is proportional to the roughness ofthe paper. Light source 16 projects a light onto the reflective member14. This light is reflected by the reflective member 14 onto theposition detector 18. As the surface engaging member 12 is displaced dueto the roughness of the paper's surface, the reflected light will movealong the position detector 18. As diagrammatically shown by theposition detector's hash marks, the position detector is calibrated in amanner such that minute displacements of the surface engaging member 12are translated to light movements along the position detector 18. Themeasured light movements along the position detector can be mapped orotherwise processed to provide roughness values or measurements thatgive an indication of the surface's roughness.

Exemplary Surface Engaging Member

As was mentioned in the above example, the surface engaging member 12 issupported in a cantilevered disposition proximate the surface of apaper. In one exemplary embodiment, the surface engaging membercomprises a thin flexure material that is dimensioned so that it can beresiliently displaced by the surface of a piece of paper as relativemovement occurs between the member 12 and the paper's surface. As anexample, consider that the surface engaging member can be fixed inplaced while the paper is moved relative to the member 12. Any suitablematerial can be utilized to form the surface engaging member or flexure.Exemplary materials include, without limitation, metal, ceramics, andvarious other materials that will be apparent to those of skill in theart. Various types of thin metal flexures can be formed from thin steelor aluminum through suitable manufacturing techniques such as stampingand the like. When metal is utilized as the flexure material, it ispossible for the upper surface of the metal flexure to be used as areflective member 14.

Consider, for example, FIGS. 2–4 which show various aspects of exemplarysurface engaging members.

FIG. 2 is a top plan view of an exemplary surface engaging member 12 ain the form of a metal flexure. Flexure 12 a has, in this example, firstand second ends 20, 22 which provide a body. In the particularconstruction shown, first end 20 is generally wider than second end 22,with the flexure body tapering between the two ends. It will beappreciated, however, that FIG. 2 constitutes but one exemplaryfootprint of a suitable flexure and that other footprints could beprovided without departing from the spirit and scope of the invention.

In this particular example, first end 20 can be dimensioned to be about5 mm in width (indicated by w1) and second end 22 can be dimensioned tobe about 2 mm in width (indicated by w2). Reflective member 14 a isprovided by the top surface of member 12 a, or can be a separatelyprovided reflective component. Adjacent second end 22, an integral tipportion 24 projects downwardly (generally into the plane of the pageupon which FIG. 2 appears). The length of the tip can be any suitablelength, with an exemplary length being about 2 mm. In this example, thetip portion 24 is integral with the body of the flexure. That is, it isdesirably formed from the same material from which the body is formed,and at the same time. The length of the flexure can be suitable length,with an exemplary length being from between about 10 cm to one inch.

FIG. 3 shows an elevational side view of the FIG. 2 flexure 12 a. Thethickness of the flexure is desirably one that can accommodate resilientmovement in response to roughness variations of paper surfaces. In thisspirit, any suitable thickness can be used. If metal material isutilized to form the flexure, then a thickness of around 0.1 mm can besufficient, depending on the metal material.

FIG. 4 shows another flexure construction 12 b in which the tip portion24 b is not integral with the flexure body. Rather, in this example, thetip portion 24 b is separate from, yet attached to or connected with theflexure proximate second end 22. Any suitable material can be used toform the tip portion. For example, the tip portion can be formed fromhardened steel or ceramic material. Other materials can, of course, beutilized.

Various tip portion constructions can be utilized. Consider, forexample, FIG. 5 which shows but three exemplary tip portionconstructions separately designated at 24 c, 24 d, and 24 e. Tip portion24 c is a needle tip construction that is exemplified in FIG. 4. Tipportion 24 d is a chisel tip construction that is exemplified in FIG. 3.Tip portion 24 e is a rounded tip construction that can be used as analternative to the other illustrated tip constructions.

Exemplary Embodiment

The above-described detection mechanism can be utilized in a variety ofscenarios in which it is desirable to detect the roughness of a papersurface. The described construction is advantageous in that it is smallin size and has only a small number of components. Additionally, directmeasurements of the paper surface topography can be provided (ascontrasted with the indirect measurement techniques of the past).Further, the inventive constructions require little or no user input,and can be conveniently configured for automated use. One such automateduse can occur within the confines of a printing device.

FIG. 6 shows an exemplary printing device in the form of a laser printeror ink jet printer 60. Printer 60 can be any suitable printer for whichit is desirable to determine the roughness of paper. Exemplary printersare available from the assignee of this document.

FIG. 7 shows an exemplary portion of printer 60 that includes structure70 that is utilized to support a portion of an exemplary roughnessdetection mechanism 10. A paper tray 72 holds a supply of paper 74 thatis ready for use in the printer. As the paper is fed, piece by piece,into the printer, detection mechanism 10 is positioned in such a mannerthat surface engaging member 12 engages each piece of paper to ascertainthe roughness of the paper. As the paper advances past the surfaceengaging member 12, the member is deflected in accordance withvariations in the paper's roughness, or variations in the roughness asbetween different pieces of paper. This, in turn, causes light that isprojected from light source 16 onto reflective member 14 to be reflectedand moved in the vertical direction along the position detector 18. Fromthe light movement along the position detector, a measure of thesurface's roughness can be ascertained.

And, while the detection mechanism is illustrated as being positioned ina specific location in the figure, it is to be appreciated andunderstood that this illustration shows but one exemplary position thatthe detection mechanism 10 can occupy within a printer. Accordingly, thedetection mechanism can be deployed at any suitable location within theprinter.

In addition, it will be appreciated that other sensing techniques can beutilized to implement the inventive techniques discussed above. Forexample, various techniques such as capacitance sensing, electromagneticresponse sensing, and piezoelectric sensing can be utilized.

Exemplary Control System

FIG. 8 shows an exemplary control system 80 that can be utilized inaccordance with the embodiments described above. Control system 80 caninclude a position detector 18 as described above. The detector outputsan analog voltage that is associated with the movement of the reflectedlight on the photodetectors of the position detector. This voltage isamplified by an amplifier 82 and then provided to an analog-to-digitalconverter 84 which converts the analog voltage to a digital value. Thedigital value is then filtered by a digital filter 86 in the form of ahigh pass filter such as a phase correct Gaussian filter. The output ofthe digital filter 86 is provided to a roughness calculation module 88which integrates the voltage input to return a single voltage thatrepresents a roughness value such as an RMS (root mean square) value.This value can then be used, in the printer embodiments, to modulateprint parameters, as by the illustrated parameter manipulator 90, thatare associated with the printing that is to take place on the paper.Parameter manipulator 90 can be implemented in any suitable hardware,software, firmware, or combination thereof. Exemplary print parametersinclude, without limitation, fuser temperature, fusing time and fusingspeed. This value might be used by the parameter modulator 90, forexample, in connection with a lookup table that contains exemplaryparameter values that are associated with various roughness values.Thus, as the roughness value is determined, the lookup table isconsulted to determine applicable print parameters that are to beutilized with that particular piece of paper.

In Operation

FIG. 9 is a flow diagram of exemplary steps in a method in accordancewith the described embodiment. The steps of the illustrated method canbe implemented in any suitable hardware, software, firmware orcombination thereof. In one exemplary embodiment, the steps areimplemented in connection with a printing device such as the onedescribed by FIGS. 6 and 7. It is to be understood, however, that otherimplementations, and particularly ones that are not necessarilyassociated with printing devices, can be provided to implement themethod about to be described.

Step 900 engages a paper surface with a surface engaging member. FIG. 1shows one exemplary construction that can be utilized to implement thisstep. It should be noted that while FIG. 1 shows a surface engagingmember having a cantilevered construction, such is not necessarily arequirement of other surface engaging members that can be utilized.Accordingly, other constructions can be utilized without departing fromthe spirit and scope of the invention. Step 902 projects light energy ator towards a reflective member that is associated with the surfaceengaging member. Again, FIG. 1 shows but one exemplary way in which thisstep can be implemented. There, the reflective member is provided as anintegral part of the surface engaging member. It is quite possible,however, for the reflective member to be provided as a separatecomponent. Step 904 receives light that is reflected by the reflectivemember. In the illustrated example of FIG. 1, this step is implementedby a position detector 18 upon which the reflected light falls. Theposition detector is spaced from the reflective member and configured sothat minute movements of the surface engaging member result in lightmovement along the position detector. Step 906 ascertains, from thereceived light, a roughness measurement of the paper surface'sroughness. Specifically, the received light moves along the positiondetector as a function of the roughness of the paper's surface. Suchlight movement can then be processed to provide a roughness measurementor value that is associated with the roughness of the paper's surface.Step 908 is an optional step and can be implemented in connection withvarious printer embodiments. In this step, the roughness measurement isused to adjust one or more printing parameters associated with paperthat is to be printed upon by a printer. Examples of printing parametersare given above.

Conclusion

The embodiments described above provide a simple, convenient way ofdetecting the surface roughness of a piece of paper. Advantages areachieved in a simple construction that is scalable for applications indevices such as printers. The described embodiments provide astandalone, self-sufficient, automated device that requires little or nooutside user intervention. By virtue of its small size and light weight,the device is easily moved or transported from one location to another.

Although the invention has been described in language specific tostructural features and/or methodological steps, it is to be understoodthat the invention defined in the appended claims is not necessarilylimited to the specific features or steps described. Rather, thespecific features and steps are disclosed as preferred forms ofimplementing the claimed invention.

1. A printing device comprising: a printer configured to print upon amedium; a surface-engaging member associated with the printer andconfigured to physically engage a medium surface, the surface-engagingmember comprising a flexure material body that is supported in acantilevered disposition proximate a piece of medium to be printed uponby the printer; a reflective member joined with the surface-engagingmember; one or more light sources in operable proximity to thereflective member and configured to project light energy toward thereflective member; and a position detector mounted in operable proximityto the reflective member and configured to receive light energy that isreflected from the reflective member, the surface-engaging member beingconfigured for displacement by the medium's surface in accordance withvariations in the roughness of the surface sufficiently so that lightthat is reflected by the reflective member and received by the positiondetector can be utilized to ascertain a measure of the medium surface'sroughness.
 2. The printing device of claim 1 further comprising acontrol system configured to modulate one or more print parameters inaccordance with the measure of the medium surface's roughness.
 3. Theprinting device of claim 2, wherein the one or more print parameters areselected from a group of parameters consisting of: fusing time, fusingspeed, toner concentration, toner developer voltage, toner transferdevice voltage, and photosensitive surface charging device voltage. 4.The printing device of claim 1 further comprising a parametermanipulator coupled with the position detector and configured tomodulate one or more print parameters in accordance with the measure ofthe medium surface's roughness.
 5. The printing device of claim 4,wherein the one or more print parameters are selected from a group ofparameters consisting of: fusing time, fusing speed, tonerconcentration, toner developer voltage, toner transfer device voltage,and photosensitive surface charging device voltage.
 6. The printingdevice of claim 1, wherein the flexure material body comprises a metalflexure material body.
 7. The printing device of claim 1, wherein theflexure material body comprises first and second ends, the body taperingbetween the two ends.
 8. The printing device of claim 1, wherein the oneor more light sources are configured to project visible light energy. 9.The printing device of claim 1, wherein the position detector issufficiently sensitive and is calibrated to detect movement of lightreflected by the reflective member in response to minute displacementsof the surface-engaging member as a result of variations in theroughness of the surface.
 10. A method of detecting the roughness of amedium surface comprising: engaging a medium surface with asurface-engaging member; projecting light energy towards a reflectivemember associated with the surface-engaging member in a manner in whichthe light energy is reflected by the reflective member; receiving lightenergy that is reflected by the reflective member; ascertaining, fromthe received fight energy, a roughness measurement of the mediumsurface's roughness; and using the roughness measurement to adjust oneor more printing parameters associated with a printer that is to printupon the medium's surface.
 11. The method of claim 10, wherein the lightenergy projected towards the reflective member comprises a visual light.12. The method of claim 10, wherein the one or more printing parametersthat are adjusted are selected from a group of parameters consisting of:fusing time, fusing speed, toner concentration, toner developer voltage,toner transfer device voltage, and photosensitive surface chargingdevice voltage.
 13. A surface roughness detection device comprising: asurface-engaging member configured to physically engage a medium surfaceand to move in response to variations along the medium surface; anelectromagnetic radiation emitting device configured to directelectromagnetic radiation towards the surface-engaging member; a sensorconfigured to receive electromagnetic radiation reflected from thesurface-engaging member, wherein the sensor is sufficiently sensitive soas to detect movement of the reflected electromagnetic radiation thatoccurs in response to movement of the surface-engaging member as aresult of variations along the medium surface; and a control systemconfigured to modulate one or more print parameters based upon thedetected movement of the electromagnetic radiation.
 14. The device ofclaim 13, wherein the surface-engaging member is cantilevered.
 15. Thedevice of claim 13, wherein the electromagnetic radiation source isconfigured to project light.
 16. The device of claim 13, wherein the oneor more print parameters is selected from a group of parametersconsisting of: fusing time, fusing speed, toner concentration, tonerdeveloper voltage, toner transfer device voltage, and photosensitivesurface charging device voltage.
 17. A printing device comprising: aprinter configured to print upon a medium; a movable surface-engagingmember associated with the printer and configured to physically engage amedium surface to be printed upon by the printer; a reflective memberjoined with the surface-engaging member; one or more light sources inoperable proximity to the reflective member and configured to projectlight energy toward the reflective member; a position detector mountedin operable proximity to the reflective member and configured to receivelight energy that is reflected from the reflective member, thesurface-engaging member being configured for displacement by themedium's surface in accordance with variations in the roughness of thesurface sufficiently so that light that is reflected by the reflectivemember and received by the position detector can be utilized toascertain a measure of the medium surface's roughness, wherein theposition detector is sufficiently sensitive and is calibrated to detectmovement of light reflected by the reflective member in response tominute displacements of the surface-engaging member as a result ofvariations in the roughness of the surface; and a parameter manipulatorcoupled with the position detector and configured to modulate one ormore print parameters in accordance with the measure of the mediumsurface's roughness, wherein the one or more printing parameters thatare adjusted are selected from a group of parameters consisting of;fusing time, fusing speed, toner concentration, toner developer voltage,toner transfer device voltage, and photosensitive surface chargingdevice voltage.